Design Process Book Designed for Simple Limb Initiative by Kyle McCormick Simple Limb Initiative: Colombia Project Description Low end-user cost prosthesis <$30 Adjustable for growth Allow Colombian children to actively work, play, and socially interact with a semblance of normalcy. Colombia is the worlds second most heavily land-mined country. Its total area is roughly twice the size of California and the most heavily mined areas are shown at left in red. The 3.6 million+ landmines deployed since the 1960s claimed a recorded 10,000+ victims since 1990 alone. The majority of these victims are children. The Land Mine Toll Formative Research There is a 41.9% dependency ratio in Colombia, meaning that a large chunk of the population is made up of dependent youth who need education and provision for until they reach an age and ability to become a self-sufcient member of society Children of Colombia Income inequality in Colombia is some of the worst in the world, and despite being up almost 10% since 2008, there is still over 32% of the population living below the poverty level. Estimations are that the poverty level in rural areas, where approximately 1/4th of the population resides, is close to double that, with closer to 64% of the population living in poverty thanks in large part to land displacement due to violence, confict and the drug trade. Rural Poverty Colombias natural resources include petroleum, natural gas, coal, iron ore, nickel, gold, copper, emeralds, hydro power. Only about 5% of Colombias arable land is cultivated limited by harsh terrain and limited irrigation. Agriculture and usable crops include cofee, corn, sugar/sugar cane, bananas, fresh-cut fowers, tobacco, yucca, plantains, potatoes, cocoa, rice, cassava, sorghum, palm oil, beans, and a few illicit plants. Resources Bamboo is a plentiful, sustainable resource that is a strong building material. Resources Colorful Culture Colombias ethnic diversity contributes a great deal to its unique culture, much of which revolves around its own Cumbia style of music which is a fusion of African beat with that of native Colombian tribes with a tinge of Caribbean-infuenced fair as well as many festivals of the Catholic faith of 90% of the population. Colombians love their sports. Soccer (ftbol) is of course the most widely played and enjoyed pastime, and can be played by any able-bodied person in any area, even remote villages. Sports and Pastimes Colombias extremely vaired and colorful crafts range from the ornate Pasto Lacquer; a layered natural resin and wood combination that creates elaborate and extremely vivid colorful table wares to moden Sombrero Vueltiao. Mola fabric is a bright and beautifully woven textile of the Kuna people, Ruana garments and pottery are found in the people of Rquira, and the elegant handcrafted bamboo Guadua furniture is associated with the craftsmen of the Paisa region. Handicrafts Distribution Partner Catholic Church Distribution Partner Catholic Church Partner Benefts: Wide reach Neutrality Safe Travel Volunteers Trust of locals Catholic Relief Services is working to deliver humanitarian aid to Colombians and their host communities; meet needs for food and non-food assistance; provide psychological, social and legal assistance... -Catholic Relief Services Our Team Design Approach 25% Local Material 25% 3D Printing 25% Mass Production 25% Local Craftsman 3D Printed Mass Produced Local Material Mass Produced Custom Made Design Strategy Custom Fit 3D Printing -Socket Mass Production - Joint Local Material - Bamboo Craftsman - Foot & Hand Ideation Knee Evolution 1 2 3 4 5 6 Bottom half of wood knee cracked. Acrylic knee showed promise. 7 8 9 9 10 11 12 9 10 11 Melted ABS knee v.1 with reprint v.2 Acrylic knee v.2 from solid blocks was highly functional. Wood knee v.2 cracked under load. cs Above Knee Prosthesis Concept 1: Wood Knee Joint PVC Joinery Bamboo Pylon PVC Joinery Polycarbonate Foot Polycarbonate, which was my frst material of choice in constructing a foot, is both hard to source inside Colombia, and is not indistructable as our testing surprisingly found. Above Knee Prosthesis Concept 2: Bamboo Pylon PVC Joinery Wood Veneer Foot Bent laminate wood fabricating was a new process to me, but turned out to be pretty successful. It has potential for application in a foot, but repeated stress may cause the wood to crack and separate as some testing showed, and its a labor-intensive process that is limited in its shapes. Above Knee Prosthesis Concept 3: Bamboo Pylon PVC Joinery Bent Stainless Sheet Metal Foot Learning to braze to attach the ankle adjustment mechanism to the revised stainless foot. Stainless steel foot is easy to bend and fabricate and allows a durable shock absorbing foot for natural gait. Stainless Foot v.2 More Ideation 3-axis adjustable knee inspired by christmas tree stand. User Needs for Leg Walk Forward Walk Backward Run Ride Bike Climb Play / Sports Terrain Work in Field Work at Home Bath 0 1 2 3 4 5 6 7 8 9 10 ychological Needs 0 1 2 3 4 5 6 7 8 9 10 Aesthetic Bamboo Color Pattern Form Metal Parts Textile 0 1 2 3 4 5 6 7 8 9 10 Decision Matrix Fabrication Heat treating bamboo to strengthen. Creates beautiful brown patina. 3D Printed ABS socket can be printed in- country in one piece or two halves like this one. Incorporated pattern allows airfow to limb as well as a woven aesthetic. Fabricating custom stainless pivot hinges for knee. Machining acrylic knee v.2 to accept hardware. Bending fnal stainless foot v.3 to optimize walking shape and soccer toe. Simulated powder coating of hardward to appear less cold and mechanical. Bill of Materials 1 -Custom 3D printed ABS socket ~ $10 of material 1 - Injection molded upper knee - $2.25/part @10,000 units* 1 - Injection molded lower knee - $2.50/part @10,000 units* 1 - 1.5 diameter bamboo pylon- locally sourced $ free 1- Rubber foot tread - locally sourced from recycled bike tire $ free 1 - 5x8 3/32 acrylic fairing - $.88 **8589K35 (out of 48x96) 1 - 1.75 ID x1.5 16ga steel ankle tube -$.47 **7767T291 1 - 5x1.5 30ga aluminum ankle shim - $.50 **9708K81 1 - Stainless sheetmetal foot (4x16 16ga) - $4.02 **8983K355 2 - 1.5 12ga stainless brackets - $.20 **8983K358 1 - 1.25 12ga stainless bracket $.08 **8983K358 3 - 5/16-8 x 2.75 socket cap sc rews - $1.69 **91251A594 1 - 5/16-8 x 1.75 socket cap sc rews - $.28 **91251A589 8 - 8-32 x1/4 stainless cone point set screws $1.08 **92785A190 4 - 5/16 Nylon locknuts - $.33 **90715A005 1 - 36x1.5 flat nylon webbing - $1.14 *** 2 - 24x3/4 flat nylon webbing - $1.12 *** 1 - 1.5 Side release buckle - $.43 *** 4 - 3/4 plastic slides- $.72 Total $28.14 * price quotes based off (custompartnet.com) injection molded part estimator **denotes McMaster-Carr part number. These are retail prices reflected above, in volume I estimate approx. 1/4 the cost. *** reflect bulk price from (strapworks.com) 21.369 8.281 9.909 11.199 10.171 6.000 5.378 3.151 Orthographics 1 -Custom 3D printed ABS socket 2 - Injection molded upper knee 3 - Injection molded lower knee 8 - 4x 5/16 socket head cap screw 11 - 2x #4 x 3/4 socket head cap screw 10 - 3 x 12ga stainless bracket 9 - 4x 5/16 nylon insert locknuts 9 - 2x #4 nylon insert locknuts 7 - 3 axis adj. ankle joint 4 - Bamboo pylon 6 - Stainless Foot 5 - Acrylic Fairing Exploded Views Parts: Tools: (1) 5/16x 1.5 (1) #5 allen key (3) 5/16x 2.75 (4) 5/16 locknuts (2) #4 locknuts (2) #4x3/4 (2) 1.5bracke (1) 1.25bracket (1) #2.5 allen key (1) small crescent wrench (1) #2 allen key Custom Parts: Individually scanned and printed 3D Socket for perfect fit Fabricated Parts : Hand bent 16ga stainless sheet foot Template for foot cutout Bend points Assembly Instructions: 3D print socket. If printed in two pieces, epoxy together. Epoxy socket to top half of included knee. Insert 2 long bolts through the long brackets and outer holes, through to outer bracket and locknuts. 12 3 6 5 4 Insert 1 long bolt through the bottom of short bracket in slot into locknut. Insert short bolt through bracket into mid section and secure with locknut. Source 1.5 dia bamboo pylon. Insert into knee bottom and secure with two small #4 socket screws and #4 locknuts. Insert bamboo pylon into ankle joint and secure and adjust angle with 8 set screws. Attach fairing to front of knee. Pre-assembly Pieces Fairing Options The fairing represents a point of end-user customizability to tailor their prosthesis to their own style and needs. It can function sans fairing, but may beneft from some added protection and fair with one attached to its universal 2 diameter lower knee. This allows for quickly fabricating a fairing out of 2 ID PVC pipe and covering it in cloth, leaving it bare, or even heat bending a piece of laser cut acrylic. 4-Bar linkage injection- molded knee. Allows for stability, natural gait and full range of motion. 3 - axis adjustable ankle. Rotational, fore/aft, and side-to-side individualized adjustment controlled by set screws. Final Locally sourced bamboo pylons are cheap, incredibly strong, replaceable to accomodate growth and wear, and sustainable. 3D Printed socket allows for personalized perfect ft to the stump. Retention straps help keep leg frmly secured even during active sports. Context Shots: